Method and apparatus for protecting concrete rail beds

ABSTRACT

An apparatus for protecting a continuous concrete rail bed, including a resilient, compressible cushion for being placed directly upon the continuous concrete rail bed and a spacer plate for being positioned onto the cushion. The cushion and spacer plate are sized and shaped to extend laterally outward in opposing directions beyond the width of the opposing flanges of a rail positioned on the spacer plate to define first and second attachment areas on opposite sides of the rail. First and second locks are provided for being positioned on a top surface of the spacer plate at the first and second attachment areas and engaging the opposing flanges of the rail for locking the rail in position on the spacer plate. First and second anchors are provided for anchoring the cushion, spacer plate and lock to the concrete bed at the respective first and second attachment areas of the spacer plate.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to a method and apparatus for protectingconcrete rail beds of the type found in rail yards where raillocomotives are matched with rail cars to form trains. A rail yard, orrailroad yard, is a complex series of railroad tracks for storing,sorting, or loading/unloading railroad cars and/or locomotives. Railroadyards have many tracks in parallel for keeping rolling stock stored offthe mainline, so that they do not obstruct the flow of traffic. Railroadcars are moved around by specially designed yard switchers, a type oflocomotive. Cars in a railroad yard may be sorted by numerouscategories, including railroad company, loaded or unloaded, destination,car type, or whether they need repairs. In many cases rails in railyards are not attached to laterally-extending sleepers, or ties, as isthe case with rails that carry locomotives and attached cars betweendestinations. Rather, large concrete beds are formed onto which therails are attached. A typical attachment method is to place a steelspacer plate at intervals along the bed onto which the rail ispositioned and held in place with keeper wedges on both sides of thespacer plate. The spacer plate is bolted to the concrete bed with anchorwedges. Spacer plates are typically 6 to 10 inches long, a quarter toone-half inch thick and spaced approximately 3-5 feet apart. The rail istherefore spaced above the concrete bed by the thickness of the spacerplate. This has the further effect of concentrating the weight of therails and of the locomotives and rolling stock onto relatively shortsegments of the concrete bed.

The concrete beds allow greater control of rail elevation, layout andsimilar factors not usually present on mainlines. The concrete beds alsopermit control of drainage of water, fuel and lubricants. These liquidsare typically captured and disposed of in a manner required byregulation to prevent soil contamination and to minimize waste.

However, the manner in which rails are presently mounted on theseconcrete beds subjects these concrete beds to severe stresses. Whereason mainline tracks the rails are under load for relatively short,intermittent periods of time, in rail yards extremely heavy locomotivesand loaded cars may sit for hours or days in the same location.Locomotives with idling engines create vibrations that pass directlythrough the rails and into the concrete beds at the positions below thespacer plates. This causes crushing and eventual disintegration of theconcrete. In cold climates water can enter the cracks and fissurescaused by this disintegration and freeze, causing further damage as theexpanding water opens the cracks and fissures further. Eventually, theconcrete is subjected to greater vibration as the spacer plate wallowsin an area of disintegrated concrete.

It has long been recognized in the prior art that on mainline railwaytracks cushioning of the rails on sleepers has the desirable effect ofdamping the intervals of compression as the steel wheels of locomotivesand rolling stock passes at speed along the rails. However, it has notbeen recognized that cushioning of rails in railway yards, wherelocomotives and rolling stock are generally stationary or moving veryslowly would also be beneficial.

SUMMARY OF THE INVENTION

Therefore, it is an object of the invention to provide an apparatus forcushioning rails on a continuous concrete railway bed such as found inrail yards.

It is a further object of the invention to provide a method ofpreventing crushing and disintegration of continuous concrete railroadbeds resulting from long term vibration and weight application.

These and other objects and advantages of the invention are achieved byproviding an apparatus for protecting a continuous concrete rail bed,comprising a resilient, compressible cushion for being placed directlyupon the continuous concrete rail bed and a spacer plate for beingpositioned onto the cushion. The cushion and spacer plate are sized andshaped to extend laterally outward in opposing directions beyond thewidth of the opposing flanges of a rail positioned on the spacer plateto define first and second attachment areas on opposite sides of therail. First and second locks are provided for being positioned on a topsurface of the spacer plate at the first and second attachment areas andengaging the opposing flanges of the rail for locking the rail inposition on the spacer plate. First and second anchors are provided foranchoring the cushion, spacer plate and lock to the concrete bed at therespective first and second attachment areas of the spacer plate.

According to one embodiment of the invention, the first and second lockseach comprise a keeper wedge having an inwardly extending shoulder forresiding against a top surface of the flange of the rail.

According to another embodiment of the invention, the cushion, spacerplate and lock each include aligned through bores for receiving ananchor wedge mounted in and extending upwardly from the concrete bed.

According to another embodiment of the invention, the cushion comprisesa sheet of styrene-butadiene rubber (SBR)/synthetic fabric beltingmaterial.

According to another embodiment of the invention, the cushion comprisesa sheet of recycled rubber tire underlayment material.

According to another embodiment of the invention, the cushion comprisesa sheet of compressed non-asbestos sheet material that includes aramidfiber.

According to another embodiment of the invention, the cushion comprisesa sprayed-on polyurea applied to the bottom of the spacer plate.

According to another embodiment of the invention, the cushion and thespacer plates have approximately the same width and length dimensions.

According to another embodiment of the invention, an apparatus isprovided for protecting a continuous concrete rail bed, comprising aresilient, compressible cushion for being placed directly upon thecontinuous concrete rail bed and a spacer plate for being positionedonto the cushion. The cushion and spacer plate have approximately thesame width and length dimensions and are sized and shaped to extendlaterally outward in opposing directions beyond the width of theopposing flanges of a rail positioned on the spacer plate to definefirst and second attachment areas on opposite sides of the rail. Firstand second locks are provided for being positioned on a top surface ofthe spacer plate at the first and second attachment areas and engagingthe opposing flanges of the rail for locking the rail in position on thespacer plate. The first and second locks each comprise a keeper wedgehaving an inwardly extending shoulder for residing against a top surfaceof the flange of the rail. First and second anchor wedges are embeddedin the concrete bed and extend upwardly through aligned bores in thecushion, spacer plate and locks for anchoring the cushion, spacer plateand lock to the concrete bed at the respective first and secondattachment areas of the spacer plate.

According to another embodiment of the invention, a method of protectinga continuous concrete rail bed is provided, and includes the steps ofdetermining an appropriate spacing along the length of a continuousconcrete rail bed for placing a plurality of apparati for protecting theconcrete rail bed. The method also provides a resilient, compressiblecushion for being placed directly upon the continuous concrete rail bedwith a spacer plate positioned onto the cushion. The cushion and spacerplate are sized and shaped to extend laterally outward in opposingdirections beyond the width of the opposing flanges of a rail positionedon the spacer plate to define first and second attachment areas onopposite sides of the rail. First and second locks are provided forbeing positioned on a top surface of the spacer plate at the first andsecond attachment areas and engaging the opposing flanges of the railfor locking the rail in position on the spacer plate, and first andsecond anchors are provided for anchoring the cushion, spacer plate andlock to the concrete bed at the respective first and second attachmentareas of the spacer plate. The first and second anchors are embedded inthe concrete rail bed on opposite sides of a space to be occupied by alength of rail, and a cushion is positioned onto the concrete rail bed.A spacer plate is positioned onto the top of the cushion and a lock isplaced onto the top of the spacer plate. The lock, spacer plate andcushion are anchored to the concrete rail bed with the first and secondanchors, and the rail is positioned onto the top of the spacer platebetween the first and second anchors. The rail is locked to the spacerplate with the locks. The method is repeated at the appropriate spacingalong the length of the concrete rail bed.

According to another embodiment of the invention, the step ofpositioning a cushion onto the concrete rail bed comprises the step ofpositioning a material selected from the group consisting of a sheet ofstyrene-butadiene rubber (SBR)/synthetic fabric belting material, asheet of recycled rubber tire underlayment material, a sheet ofcompressed non-asbestos sheet material that includes aramid fiber and asprayed-on polyurea applied to the bottom of the spacer plate.

According to another embodiment of the invention, the first and secondlocks comprise first and second keeper wedges, each having aninwardly-extending shoulder for being positioned over respective flangesof the rail.

According to another embodiment of the invention, the method includessteps of forming aligned through bores in the cushion, spacer plate andlock for receiving an anchor wedge mounted in and extending upwardlyfrom the concrete bed.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The present invention is best understood when the following detaileddescription of the invention is read with reference to the accompanyingdrawings, in which:

FIG. 1 is a perspective view of a prior art means of attaching a rail toa concrete bed; FIG. 2 is a perspective view of a novel attachmentapparatus, viewed from one side, for attaching a rail to a concrete bedaccording to one preferred embodiment of the invention;

FIG. 3 is an exploded view of the attachment apparatus of FIG. 2;

FIG. 4 is a vertical cross-section of the attachment apparatus of FIG.2; and

FIG. 5 is a perspective view of a section of rail on a continuousconcrete bed attached with the apparatus of FIGS. 2-4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now specifically to the drawings, FIG. 1 shows a prior artapparatus 10 for attaching a rail “R” to a continuous concrete bed. Asteel spacer plate 12 is positioned directly onto a continuous concretebed “C”. Similar spacer plates 12 are positioned at intervals along thepath of the railway and a rail is positioned onto the spacer plates 12with a section of the spacer plates 12 exposed on opposite sides. Thespacer plates 12 are anchored to the concrete bed “C” by anchor wedges,such as anchor wedge 14, the threaded portion of which is shown. Akeeper wedge 16 is placed onto the anchor wedge 14 and sits on thespacer plate 12. The keeper wedge 16 is then locked into place bytightening a washer 18 and nut 20 onto the threaded portion of theanchor wedge 14. The shoulder of the keeper wedge 16 extends over theflange of the rail “R”, locking it into position on the spacer plate 12and the concrete bed “C”.

Referring now to FIGS. 2-5, an apparatus 30 for securing a rail to acontinuous concrete bed “C” is shown. A vibration-damping cushion 32according to one of several alternative embodiments, described infurther detail below, is placed directly onto the concrete bed “C.” Asteel spacer plate 34 having approximately the same dimensions as thecushion 32 is positioned onto the cushion 32.

As shown in FIG. 3, the cushion 32 and spacer plate 34 are formed withholes 36, 38, respectively, through which anchor wedges 40 are extended.The anchor wedges 40 are anchored into bores “B” drilled into theconcrete bed “C”.

Similar cushions 32 and spacer plates 34 are positioned at intervalsalong the path of the railway and a rail “R” is positioned onto thespacer plates 34 with a section of the each cushion 32 and spacer plate34 exposed on opposite sides of the rail “R”. See FIGS. 4 and 5. Akeeper wedge 42 is placed onto each anchor wedge 40 and sits on therespective spacer plate 34. The keeper wedges 42 are then locked intoplace by tightening a washer 44 and nut 46 onto the threaded portion ofthe anchor wedge 40. The shoulders of the keeper wedges 42 extend overthe flanges on each side of the rail “R”, locking it into position onthe spacer plate 34 and the concrete bed “C”, as best shown in FIG. 4.The cushions 32 provide protection against crushing and eventualdisintegration of the concrete beneath the spacer plates 34. Severalalternative materials for the cushions are available.

Example 1

Styrene-butadiene rubber (SBR)/synthetic fabric belting material, 2 Ply220 Black 3/16× 1/16″ (total thickness ¼″) such as manufactured byBeltservice Corporation.

Example 2

Recycled rubber tire underlayment material, such as manufactured byEcore International, ¼″ (specified as 6 mm) thick. This porous productis most suitable for warm climates where freezing of water in theporosities of the material is not a concern.

Example 3

Compressed non-asbestos sheet material, such as manufactured by TexcelRubber, ⅛″ thick, Part No. SEAL-G-4. This material is fabricated ofaramid fiber, inorganic fiber and a nitrile binder.

Example 4

Sprayed-on polyurea applied to the bottom of the spacer plate 34 at athickness of 1/16″.

These materials absorb vibration and continuous compression caused bylocomotives and rolling stock, particularly vibration caused bystationary, idling locomotives. The material of Example 1 is consideredthe preferable material based on cost, ease of application and wearlongevity.

A method and apparatus for protecting concrete rail beds according tothe invention have been described with reference to specific embodimentsand examples. Various details of the invention may be changed withoutdeparting from the scope of the invention. Furthermore, the foregoingdescription of the preferred embodiments of the invention and best modefor practicing the invention are provided for the purpose ofillustration only and not for the purpose of limitation, the inventionbeing defined by the claims.

I claim:
 1. An apparatus for protecting a continuous concrete rail bed,comprising: (a) a resilient, compressible cushion for being placeddirectly upon the continuous concrete rail bed; (b) a spacer plate forbeing positioned onto the cushion; (c) the cushion and spacer platesized and shaped to extend laterally outward in opposing directionsbeyond the width of the opposing flanges of a rail positioned on thespacer plate to define first and second attachment areas on oppositesides of the rail; (d) first and second locks for being positioned on atop surface of the spacer plate at the first and second attachment areasand engaging the opposing flanges of the rail for locking the rail inposition on the spacer plate; and (e) first and second anchors foranchoring the cushion, spacer plate and lock to the concrete bed at therespective first and second attachment areas of the spacer plate.
 2. Anapparatus according to claim 1, wherein the first and second locks eachcomprise a keeper wedge having an inwardly extending shoulder forresiding against a top surface of the flange of the rail.
 3. Anapparatus according to claim 1, wherein the cushion, spacer plate andlock each include aligned through bores for receiving an anchor wedgemounted in and extending upwardly from the concrete bed.
 4. An apparatusaccording to claim 1, wherein the cushion comprises a sheet ofstyrene-butadiene rubber (SBR)/synthetic fabric belting material.
 5. Anapparatus according to claim 1, wherein the cushion comprises a sheet ofrecycled rubber tire underlayment material.
 6. An apparatus according toclaim 1, wherein the cushion comprises a sheet of compressednon-asbestos sheet material that includes aramid fiber.
 7. An apparatusaccording to claim 1, wherein the cushion comprises a sprayed-onpolyurea applied to the bottom of the spacer plate.
 8. An apparatusaccording to claim 1, wherein the cushion and the spacer plates haveapproximately the same width and length dimensions.
 9. An apparatus forprotecting a continuous concrete rail bed, comprising: (a) a resilient,compressible cushion for being placed directly upon the continuousconcrete rail bed; (b) a spacer plate for being positioned onto thecushion; (c) the cushion and spacer plate having approximately the samewidth and length dimensions and sized and shaped to extend laterallyoutward in opposing directions beyond the width of the opposing flangesof a rail positioned on the spacer plate to define first and secondattachment areas on opposite sides of the rail; (d) first and secondlocks for being positioned on a top surface of the spacer plate at thefirst and second attachment areas and engaging the opposing flanges ofthe rail for locking the rail in position on the spacer plate, whereinthe first and second locks each comprise a keeper wedge having aninwardly extending shoulder for residing against a top surface of theflange of the rail; and (e) first and second anchor wedges embedded inthe concrete bed and extending upwardly through aligned through bores inthe cushion, spacer plate and locks for anchoring the cushion, spacerplate and lock to the concrete bed at the respective first and secondattachment areas of the spacer plate.
 10. An apparatus according toclaim 9, wherein the first and second locks each comprise a keeper wedgehaving an inwardly extending shoulder for residing against a top surfaceof the flange of the rail.
 11. A method of protecting a continuousconcrete rail bed, and including the steps of: (a) determining anappropriate spacing along the length of a continuous concrete rail bedfor placing a plurality of apparati for protecting the concrete railbed; (b) providing: (i) a resilient, compressible cushion for beingplaced directly upon the continuous concrete rail bed; (ii) a spacerplate for being positioned onto the cushion; (iii) the cushion andspacer plate sized and shaped to extend laterally outward in opposingdirections beyond the width of the opposing flanges of a rail positionedon the spacer plate to define first and second attachment areas onopposite sides of the rail; (iv) first and second locks for beingpositioned on a top surface of the spacer plate at the first and secondattachment areas and engaging the opposing flanges of the rail forlocking the rail in position on the spacer plate; and (v) first andsecond anchors for anchoring the cushion, spacer plate and lock to theconcrete bed at the respective first and second attachment areas of thespacer plate; (c) embedding the first and second anchors in the concreterail bed on opposite sides a space to be occupied by a length of rail;(d) positioning a cushion onto the concrete rail bed; (e) positioning aspacer plate onto the top of the cushion; (f) positioning a lock ontothe top of the spacer plate; (g) anchoring the lock, spacer plate andcushion to the concrete bed with the first and second anchors; (h)placing the rail onto the top of the spacer plate between the first andsecond anchors; (i) locking the rail to the spacer plate with the locks;and (j) repeating steps (b) through (i) at the appropriate spacing alongthe length of the concrete rail bed.
 12. A method according to claim 11,and wherein the step of positioning a cushion onto the concrete rail bedcomprises the step of positioning a material selected from the groupconsisting of a sheet of styrene-butadiene rubber (SBR)/synthetic fabricbelting material, a sheet of recycled rubber tire underlayment material,a sheet of compressed non-asbestos sheet material that includes aramidfiber and a sprayed-on polyurea applied to the bottom of the spacerplate.
 13. A method according to claim 11, wherein the first and secondlocks comprise first and second keeper wedges, each having aninwardly-extending shoulder for being positioned over respective flangesof the rail.
 14. A method according to claim 11, and including steps offorming aligned through bores in the cushion, spacer plate and lock forreceiving an anchor wedge mounted in and extending upwardly from theconcrete bed.